Pressure sensing film aids ultrasonic welding

12 May 2010 Manufacturing / Production Technology, Hardware & Services

Ultrasonic welding (USW) is a joining technique that uses high-frequency ultrasonic acoustic vibrations to create solid-state welds. In the electronic, computer and electrical industries, ultrasonic welding is often used to join wired connections and to create connections in small, delicate circuits. Junctions of wire harnesses are often joined using ultrasonic welding. Electric motors, field coils, transformers and capacitors may also be assembled with ultrasonic welding.

In microelectronics, it creates reliable bonds without introducing impurities or thermal distortion into components. Semiconductor devices, transistors and diodes are often connected by thin aluminium and gold wires using ultrasonic welding. It is also used for bonding wiring and ribbons, as well as entire chips to microcircuits.

To optimise the weld and prevent defects, the horn and anvil must be precisely aligned during setup so that the horn exerts uniform pressure across the entire weld area. An economical and precise procedure that will ensure this outcome involves the use of Sensor Products’ Pressurex pressure indicating sensor film.

Routine use of Pressurex during the setup of ultrasonic welders helps ensure proper contact pressure and alignment between the horn and anvil, which results in welds of greater bond strength and aids in reducing rejected product and lowering base factory cost.

Pressurex is an easy-to-use tool that reveals the distribution and magnitude of pressure between any two contacting surfaces. When placed between the horn and the anvil of the ultrasonic bonder, the film instantaneously and permanently changes colour directly proportional to the actual pressure applied. The precise pressure magnitude is then easily determined by comparing colour variation results to a colour correlation chart (conceptually similar to interpreting Litmus paper). If desired, the film can be further analysed. Pressurex is extremely thin (4 to 8 mils) and flexible, which enables it to conform to curved surfaces.

For more information visit www.sensorprod.com

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